NEW GIZA UNIVERSITY

Building HN-02-A

SECTION 15549
INSULATION

PART 1 GENERAL

1.1 GENERAL

A. Drawings and general provisions of Contract, including General and Special

Conditions and Division-1 Specification Sections, apply to work of this Section.

B. The requirements specified in this section apply to all related sections in this
Division. The requirements of all related sections, elsewhere in this division
also apply to this section unless specified to the contrary.

1.2 DESCRIPTION OF WORK

A. The work includes the providing of all labor, supervision, materials, equipment,
accessories, services and tests necessary to complete, make ready, and set to
work for operation by the Owner, all insulation in accordance with Drawings
and Specifications.

1.3 QUALITY ASSURANCE

A. Acceptable manufacturers: Firms regularly engaged in manufacture of

insulation of the types and materials, sizes and capacities required, whose
products have been in satisfactory use in similar service for not less than 5 years
as approved by Engineer.

B. Standards Compliance: Comply with requirements of applicable Local codes

and the standards outlined in Section 15020.

1.4 SUBMITTALS

A. Shop Drawings: Shop detail drawings, including method of attachment.

B. Product Data: Manufacturer's printed data, catalog cuts, test data and
recommendations.

C. Samples, when requested.

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D. Instructions: Installation instructions.

1.5 PRODUCT DELIVERY AND STORAGE

A. Deliver material properly labeled, packaged and undamaged.

B. Do not store exposed to weather, provide suitable material to protect from

damage.

PART 2 PRODUCTS

2.1 INSULATION

A. General Insulation Requirements:

1. Insulation shall be applied on clean dry surfaces, after pressure testing

inspection and release for insulation application.

2. Insulation shall be continuous through wall, floor, ceiling openings and

sleeves. Where insulated piping or ductwork pierces fire rated
partitions, walls and floors, substitute anhydrous calcium silicate
insulation with vapor barrier in lieu of fiberglass for a minimum of
200mm from wall in both directions, to produce a hard surface for fire
resistive packing.

3. Insulation on cold surfaces where vapor barrier jackets are used shall be
applied with a continuous, unbroken vapor seal. Hangers, supports,
anchors, etc., that are secured directly to cold services shall be
adequately insulated and vapor sealed to prevent condensation.

4. Insulation pipe hanger shields shall be installed at hangers for insulated

piping. At point of support, pipe shall be protected by a 360 degree
insert of high density, 689 kPa water proofed calcium silicate, encased
in a 360 degree galvanized sheet metal shield. Insert shall be of same
thickness as adjoining pipe insulation. Shield length and minimum sheet
metal gauge shall conform to the following schedule.

Pipe Size mm Shield Length Minimum Thickness mm

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15-40 100 mm .63

50-150 150 mm 1.1
200-250 220 mm 1.8
300-450 300 mm 1.8
500 and up 450 mm 1.8

Insulation insert to extend 25 mm beyond sheet metal shield on all

insulated lines. Model types shall be standard catalog items for specific
application. Shields shall be installed in full accordance with
manufacturer's recommendations.

5. Insulation on indoor work shall have composite (insulation, jacket or

facing, and adhesive used to adhere the facing or jacket to the insulation.
Insulation shall be flame retardant essentially non combustible, and shall
not produce toxic vapors or dense smoke when burned.

6. Accessories such as adhesives, mastics, coatings, cements, tapes, etc. for

fittings shall have the same component rating as listed above and shall
be applied in strict accordance with manufacturer's instructions
including recommended coverages. Treatment of jackets or facings to
impart flame-and-smoke safety shall be permanent. The use of
water-soluble treatments is prohibited.

7. The only exception to the above material requirements is where a

material meeting these requirements is not available from any
manufacturer, in which case substitute items shall be subject to
individual approval by the Architect.

8. Where insulation is specified for piping, insulate similarly all

connection, vents, drains and any piping connected to system subject to
heat loss or gain.

9. Adhesives and coating shall be applied according to the manufacturers

standard insulation instructions. No adhesive or cements shall be
applied to ambient temperatures below those recommended by
manufacturers.

2.2 INSULATION THICKNESS AND TYPE OF APPLICATION

A. Piping systems described shall be insulated as follows, including all flanges,

fittings, valves, expansion joints, vents, drains and all other parts of the system. All

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piping subject to freezing such as in outdoor air or discharge plenums or outdoors

shall be insulated with twice the insulation thickness specified herein.

Insulation Insulation
Piping System Thickness Type

Primary and secondary

chilled water supply
and return Below 50 mm = 38mm P-1
50mm To 200mm =50mm
200mm & Up=65mm
Refrigerant suction 25 mm P-5

Outdoor condenser 50 mm P-1

water

Outdoor domestic 50 mm P-1

water (for lengths
see Plumbing dwgs)

Drain piping from

fan coil units 25 mm P-2

Drains from A.C. 25 mm P-2

units, cooling coil
drip pans, and mis-
cellaneous piping
subject to sweating

Engine Exhaust 75 mm P-4

Secondary chilled water 25 mm P-1

branches to fan
coil units
(copper tubing)

Secondary Heating water 25 mm P-3

and secondary hot
branches to fan
coil units.

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Heating water supply & Below 25mm = 25mm P-3

return 37C to 35 mm to P-3
122C 100 mm = 38 mm P-3
125 mm & up - 50 mm

Steam supply, return

and pump discharge
(0 to 103 kpa)
Up to 25mm IPS 25mm P-3
30mm to 100 IPS 50mm P-3
125 IPS and larger 63mm P-3

Steam supply and return

110 kpa to 378 kpa
Up to 25mm 38mm P-3
30mm to 50mm 50mm P-3
63mm to 100mm 63mm P-3
125mm IPS and larger 75mm P-3

Steam supply and return

385 kpa to 1378 kpa
Up to 25mm 38mm P-3
30mm to 50mm 63mm P-3
63mm to 100mm 75mm P-3
125mm and larger 100mm P-3

Thermal fluid (hot oil)

Up to 100mm (2) 38mm layers P-4
Over 100mm (2) 50mm layers P-4

2.3 PIPING INSULATION TYPES

A. Type P-1 Glass Fiber for Cold Pipes

1. Insulation shall be glass fiber with a maximum K factor of .24 at 23C

mean temperature with factory applied vapor barrier jacket.

2. Longitudinal lap and 75 mm wide vapor barrier joint seal strips shall be
adhered neatly in place with vapor barrier adhesive. Factory applied
self-sealing laps are acceptable.

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3. Ends of pipe insulation shall be sealed off with vapor barrier coating at
flanges, valves and fittings and at intervals of not more than 7 meters on
continuous runs of pipe.

4. Fittings and valves shall be insulated with molded fittings, mitered

segments of pipe insulation or 0.45 kg fiberglass blanket, compressed 2
to 1. Secure with copper-clad wire. Thickness to be same as adjoining
insulation (minimum of 25 mm thickness on fiberglass blanket).
Flanges shall be insulated with sectional pipe insulation extending a
minimum of 25 mm beyond end of bolts. Bolt area shall be filled with
insulating cement. Fittings, etc. shall be vapor-sealed by applying two
1.5 mm thick coats of vapor barrier coating reinforced with glass fabric
(10 x 10). Lap the glass fabric at least 25 mm on itself and 50 mm on
adjoining pipe insulation. If fiberglass blanket is used, a smoothing coat
of finishing cement must be applied before the vapor barrier is applied.

5. Concealed piping shall be banded in place with three aluminum bands

per section, one over each end of the joint sealing strip, and one in the
middle of the section. Where self-sealing laps are used, bands are not
required.

6. All exposed piping shall have a factory attached, pre-sized glass cloth
covered vapor barrier jacket. Vapor-barrier jacket may be vinyl-coated
embossed laminate.

7. Piping insulation density is not less than 96 Kg/cu . m .

B. Type P-2 Glass Fiber for Anti-Sweat Insulation

1. Insulation shall be glass fiber with a maximum K factor of .24 at 23C

mean temperature with factory applied vapor barrier jacket.

2. Longitudinal lap and 75 mm wide vapor barrier joint seal strips shall be
adhered neatly in place with vapor barrier adhesive. Factory applied
self-sealing laps are acceptable.

3. Fittings and valves for pipe sizes smaller than 200 mm shall be insulated
and finished with Insulating and Finishing Cement. On pipe sizes 200
mm and larger, use segments of the molded insulation or molded
fiberglass fittings wired securely in place. Flanges shall be insulated
with sectional pipe insulation extending a minimum of 25 mm beyond
the end of the bolts. Bolt area to be filled with mineral wool cement.
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Thickness of fittings, valve and flange insulation shall be same as

adjoining pipe insulation. Concealed fittings, etc., may be insulated with
0.45 kg fiberglass blanket wrapped firmly under compression, 2 to 1 and
secured with copper-clad wire.

4. Concealed piping shall be banded in place with three aluminum bands

per section, one over each end of the joint sealing strip and one in the
middle of the section. Where self-sealing laps are used, bands are not
required.

5. All exposed piping shall have a factory attached, white, all-service

jacket (ASJ). Exposed fittings, etc., shall be finished with open weave
glass fabric (10 x 10) smoothly adhered and coated with lagging
adhesive.

6. Piping insulation density is not less than 96 Kg/cu . m .

C. Type P-3 Glass Fiber Pipe Insulation for heating Pipes

1. Insulation shall be molded glass fiber with a maximum K factor of 0.24

at 23C mean temperature with factory applied jacket.

2. Longitudinal lap and 75 mm wide joint seal strips shall be secured with
outward clinch staples on concealed piping and vapor barrier adhesive
on exposed piping. Factory applied self-sealing laps (SSL) are
acceptable.

3. Fittings and valves for pipe sizes smaller than 200 mm shall be insulated
and finished with Insulating and Finishing Cement. On pipe sizes 200
mm and larger, use segments of the molded insulation or molded
fiberglass fittings wired securely in place. Flanges shall be insulated
with sectional pipe insulation extending a minimum of 25 mm beyond
the end of the bolts. Bolt area to be filled with mineral wool cement.
Thickness of fittings, valve and flange insulation shall be same as
adjoining pipe insulation. Concealed fittings, etc., may be insulated with
0.45 kg fiberglass blanket wrapped firmly under compression, 2 to 1 and
secured with copper-clad wire.

4. All exposed piping shall be finished with a factory attached, all-service

jacket (ASJ). Exposed fittings, etc., shall be finished with open weave
glass fabric (10 x 20) adhered and coated with lagging adhesive.

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5. Piping insulation density is not less than 96 Kg/cu . m .

D. Type P-4 Calcium Silicate Pipe Insulation.

1. Insulation shall be 132 kg per cu. m. density molded a hydrous calcium
silicate with a maximum K factor of 0.42 at 93C mean temperature.
Insulation shall be fastened in place with 1.7 m copper-clad wire on 450
mm maximum centers.

a. All insulation shall consist of half-round sections in single-layer

thickness.

b. Multi-layered or multi-segmental insulation is unacceptable.

2. Fittings and valves for pipe sizes smaller than 200 mm shall be insulated
and finished with Insulating and Finishing Cement to a thickness equal
to the adjoining pipe insulation. Fittings and valves for pipe sizes 200
mm and larger shall be insulated with segments of the molded insulation
wired securely in place and finished with a smoothing coat of finishing
cement.

3. Flanges shall be insulated with sectional pipe insulation extending a

minimum of 25 mm beyond the ends of the bolt. Bolt area shall be
filled with mineral wool cement.

4. Flanges and welded joints shall not be covered until the piping has been
hydrostatically tested per section 15510 of this specification.

E. Type P-5 Closed Cell Structure for Anti-Sweat Insulation

1. Insulation shall be polyolefin slip over pipe type with a maximum K

factor of .24 at 23C mean temperature.

2. Longitudinal open self sealing butt joint with pre-glued seal strips shall
be adhered neatly in place.

3. Ends of pipe insulation shall be sealed using a fuse seal gun and glue
sticks.

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2.4 INSULATION FOR SHEET METAL

A. Note that ductwork and casings which are acoustically lined, as described
elsewhere, need not be insulated on the exterior.

B. Insulate sheet metal as follows:

1. Air supply system casings and plenums including all equipment from air
intake plenum to fan discharge 37 mm type D-2, (exceptions as noted on
plans).

2. Air conditioning system supply ducts in equipment rooms - 37 mm type

D-2.

3. Air conditioning supply and return air ducts in other than equipment
rooms - 37 mm type D-1.

4. All exhaust air ducts shall be un-insulated except where external or

internal acoustic treatment is required.

5. All outside air ducts and plenums and plenums containing a percentage
of outside air on inlet side of air supply systems. 25 mm type D-2.

6. All pool supply ducts between walls of double wall ductwork (see
Section 15768) 37 mm type D-2.

2.5 PIPE SLEEVES AND DUCT OPENINGS

A. All pipe sleeves and duct openings penetrating floor slabs, partitions, walls, etc.,
shall be packed with fiberglass and sealed with mineral wool.

2.6 INSULATION TYPES

A. Type D-1 Flexible Duct Insulation with Vapor Barrier.

1. Flexible duct insulation shall be 32 kg per cu. m. density glass fiber with
maximum K factor of 0.29 at 23C mean temperature, with reinforced
foil-faced, flame resistant kraft vapor barrier.

2. Insulation shall be secured with duct adhesive. All joints shall be sealed
by adhering a 50 mm sealing lap at all joints with vapor barrier adhesive

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or 75 mm strips of vapor barrier jacket applied with vapor barrier

adhesive.

Insulation shall then be fastened with 1.7 mm copper-clad wire or

fiberglass cord on 300 mm centers. On ducts over 600 mm wide,
welded pins and clips shall be used on the underside.

3. Exposed round ducts shall have a white vinyl reinforced foil vapor
barrier. Application same except wires shall be omitted and blanket
shall be secured by stapling 50 mm longitudinal lap. Staples shall be
coated with vapor barrier coating.

B. Type D-2 Rigid Duct Insulation with Vapor Barrier.

1. Rigid duct insulation shall be 96 kg per cu. m. density glass fiber with
maximum K factor of .24 at 23C mean temperature with ASJ exposed
vapor barrier facing.

2. Insulation shall be impaled over welded pins applied to duct surface on

300 to 450 mm centers. Use a minimum of two rows of fasteners on
each side of duct. Secure insulation with suitable speed washers or clips
firmly imbedded into insulation.

3. All joints and voids in the insulation shall be filled with Mineral Wool
Cement. All joints, speed washers and breaks in the vapor barrier shall
be sealed with 75 mm wide strips of the vapor barrier facing adhered
with vapor barrier adhesive.

4. Exposed ductwork shall have a white vinyl reinforced foil vapor barrier
facing. Care shall be taken in sealing joints speed washers, etc., with
matching 75 mm or 125 mm tape of vapor barrier to insure good
appearance.

C. Type D-3 Flexible Duct Insulation for heating Ducts.

1. Flexible duct insulation shall be 24 kg per cu. m. density glass fiber

with a maximum K factor of 0.29 at 23C mean temperature.

2. Insulation shall be secured with an adhesive. But all edges of insulation

on exposed ducts and lap all edges of insulation 50 mm on concealed
duct. Insulation shall then be fastened with 1.7 mm copper-clad wire
on 300 mm centers.
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3. Exposed ducts shall have white vinyl, reinforced foil facing. Secured
by stapling a 50 mm longitudinal lap and eliminate wire.

2.7 INSULATION FOR EQUIPMENT AND SPECIAL SYSTEMS

A. The following Cold Equipment shall be insulated with vapor barrier board
insulation using Type E-1 insulation:

1. Centrifugal Refrigeration Equipment - 50 mm.

2. Evaporators, Dehumidifiers and Exchangers - 50 mm.

3. Chilled Water Pumps, and Expansion Tanks - 25 mm.

4. Single Inlet Fans Downstream of Cooling Coils - 50 mm.

2.8 INSULATION FOR HOT EQUIPMENT

A. The following Hot Equipment shall be insulated with semi-rigid insulation

using Type E-2 insulation.

1. Generator 121C. Max. 25 mm.

2. Compression Tank - 121C max. 50 mm.

B. The following hot equipment and system components shall be insulated with
high temperature block insulation using Type E-3 insulation:

1. Kitchen Range Exhaust Ducts and Fans - 50 mm.

2. Flues - 50 mm.

C. Type E-1 Glass Fiber Rigid Equipment Insulation with Vapor Barrier.

1. Insulation shall be 96 kg per cu. m. density glass fiber with vapor barrier
facing and having a maximum K factor of 0.24 at 23C mean
temperature.

2. Insulation shall be firmly held in place with copper-clad wire or pins and
clips on 300 mm centers.

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3. All joints and voids in the insulation shall be filled with mineral wool
cement. All joints and breaks in the vapor barrier shall be sealed with
strips of the vapor barrier facing adhered with vapor barrier adhesive.

4. Finish shall consist of imbedding an open weave glass fabric (20 x 20)
into wet coating of lagging adhesive over-lapping the seams at least 50
mm. A finish coat of lagging adhesive shall then be applied.

5. Sections of equipment requiring periodic servicing such as heads and

pumps shall be insulated with flanged, sectional, gasketed vaportight
aluminum sheet metal covers 1.2mm thick lined with 50mm 67 kg
density fiberglass board.

D. Type E-2 Glass Fiber Rigid Equipment Insulation for Hot Equipment.

1. Insulation shall be 96 kg per cu. m. density glass fiber having a

maximum K factor of .24 at 23C mean temperature.

2. Insulation shall be firmly held in place with copper clad wire or pins and
clips on 300 mm center.

3. All joints and voids in the insulation shall be filled with mineral wool
cement.

4. Over the insulation apply 25 mm galvanized wire netting secured to the

bands or wires and pulled down tight. Then apply 1 coat of Insulating
and Finishing Cement troweled to a smooth finish.

5. Exposed equipment shall be finished by embedding open weave glass

fabric (20 x 20) into wet coating of lagging adhesive overlapping seams
50 mm. A finished coat of lagging adhesive shall then be applied.

6. Section of equipment requiring periodic servicing such as heads and

pumps shall be insulated with sheet metal cover lined with 67 kg density
fiberglass board.

E. Type E-3 High Temperature Block Insulation for Hot Equipment.

1. High temperature insulation shall be 192 kg per cu. m. density molded

hydrous calcium silicate with a maximum K factor of 0.24 at 79C mean
temperature.

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2. Insulation shall be securely wired in place with copper clad wire or

galvanized steel bands 12 x 0.4 mm on 300 mm centers.

3. All joints and voids in the insulation shall be filled and pointed with
mineral wool cement.

4. Over the insulation apply 25 mm galvanized wire netting secured to the

bands or wires and pulled down tight. Then apply 1 coat of Insulating
and Finishing Cement troweled to a smooth finish.

5. Exposed equipment shall be finished by embedding open weave glass

fabric (20 x 20) into wet coating of lagging adhesive, overlapping all
seams 50 mm. A finished coat of lagging adhesive shall then be applied.

2.9 ALUMINUM ACCESS COVERS

A. Sections of equipment requiring periodic servicing shall be installed with

aluminum covers lined with the same thickness of material as the adjoining
insulation.

2.10 WEATHERPROOFING FINISHES FOR OUTDOOR INSULATION

A. Outdoor Piping and Round Duct

1. Finish with a 0.4 mm thick aluminum jacket which has a factory applied
moisture barrier. For all applications where it is available, the jacketing
shall be factory attached to the insulation and installed per
manufacturer's recommendation.

2. Where field applied jacketing must be used, it shall be applied with 50

mm overlap facing down from the weather and shall be secured with an
aluminum band 12 x .3 mm and seals applied on 300 mm centers with
bands applied directly over but overlaps. As an alternate, the jacketing
may be applied with rivets. Where jacketing is cut out or abutts an
un-insulated surface, the joint shall be sealed with foam sealant.

3. Fittings and valves shall be insulated and finished with mitered sections
of the insulation with factory attached aluminum jackets installed per
manufacturer's recommendation.

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B. Outdoor Equipment, Rectangular Duct Work and Irregular Surfaces.

1. The insulated surfaces shall be weather protected with two coats of

mastic, with open weave glass cloth membrane imbedded between the
coats. Embed 38mm x 38mm .7mm perforated galvanized steel angles
on all corners in mastic. The total thickness of the coating shall be a
minimum of 3 mm.

C. Where exposed indoor pipe and ductwork insulation is subject to physical

damage or abuse, such as pump rooms and fan rooms, install aluminum
jacketing equivalent to outdoor weatherproofing finishes.

D. Where piping or ductwork insulation is subject to foot traffic or similar

conditions provide galvanized steel stairs with handrails or appropriate bridges
over piping.

PART 3 EXECUTION

3.1 INSTALLATION

A. Install insulation in accordance with approved installation drawings and manufactur-

er's recommendations.

END OF SECTION 15549

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